Method of making vehicle body panels



Novfl 12, 1935.

A. P. BALL METHOD OF MAKING VEHICLE BODY PANELS 2 Sheets-Sheet 1 wINVENTOR filberi 7D. ,BdZZ.

Filed Oct. 6, 1932 CM Q- E I I ATTORN Y5.

Nov; 12, 1935. A. P. BALL 2,021,095

METHOD OF MAKING VEHICLE BODY PANELS Filed Oct. 6, 1932 2 Sheets-Sheet 2ATTORNEYS.

Patented Nov. 12, 1935 METHOD OF MAKING VEHICLE BODY PANELS Albert P.Ball, Detroit, Mich., assignor to Briggs Manufacturing Company, Detroit,Mich, a corporation of Michigan Application October 6, 1932, Serial No.636,544

3 Claims. (01. 1542) This invention relates to a method and apparatusfor producing panels for automobile bodies, such panels being formedfrom relatively flexible sheet material and in their completed formusually containing patterns or designs which may be in the nature ofembossed or pressed portions, or may be openings or cut out portionspunched or pierced from the material. The invention is particularlyadvantageous in the production of trim panels which are ordinarily ofcomposite formation and usually comprise backing strips of relativelystill but flexible material, such as fiber or cardboard, and facingstrips of cloth fabric which form the exposed interior trim of theautomobile body.

An object of the invention is to provide a method and apparatus forproducing these panels in a continuous manner whereby substantialsavings in direct labor costs, equipment, and other manufacturing costsare obtained and whereby the time required to perform the 'variousoperations on the panel blanks is materially reduced.

A further object of the invention is to provide an improved method andapparatus for making trim panels for automobile bodies in which afoundation or backing strip and a fabric strip are cemented together andpattern portions are formed in the composite strip by rollers, and inwhich the edges of the combined strips may be trimmed and panels cutfrom the strip substantially at the same time while the strip travelscontinuously through the machine.

A further object of the invention is to provide a method and apparatusfor producing panels of laminated or composite formation in which aplurality of separate strips of material are cemented together orotherwise permanently united, in which pattern or design portions arepressed into the composite strip and in which the strip is trimmed andcut into a succession of similar panels during the continuous travel ofthe strip through the machine.

A further object of the invention is to produce in a continuous manner acomposite laminated strip having a succession of similar designs orpatterns repeated in the length of the strip whereby the strip may becut or sheared into a succession of automobile body trim panels eachhaving the same design or pattern integrally formed therein.

Other objects of this invention will appear in I the followingdescription and appended claims,

Fig. '1 is a side elevation, partly in section and partly diagrammatic,illustrating one form of apparatus for carrying out the presentinvention.

Fig, 2 is a plan view of. the structure shown in Fig. 1. 5 Fig. 3 is avertical section taken through line 3-3 of Fig. 2 in the direction ofthe arrows.

Fig. 4 is'a section taken through line 4-4 of Fig. 2 in the direction ofthe arrows.

Fig. 5 is a diagrammatic side elevation illus- 10 trating another formof apparatus for carrying out the invention.

Fig. 6 is a plan view of the construction shown in Fig. 5.

Fig. 7 is a view, partly in section, taken through 15 line 1-1 of Fig.5.

Fig. 8 is a section taken through line 88 of Fig. 6.

Before explaining in detail the present invention it is to be understoodthat the'invention is 20 not limited in its application to the detailsof construction and arrangement of parts illustrated in the accompanyingdrawings, since the invention is capable of other embodiments and ofbeing practiced or carried out in various ways. Also 25 it is to beunderstood that the phraseology or terminology employed herein is forthe purpose of description and not of. limitation,,and it is notintended to limit the invention claimed herein beyond the requirementsof the prior art. 30 The embodiment of the invention illustrated inFigs. 1 to 4 inclusive is particularly adapted for the purpose ofproducing in a continuous manner composite trim panels for automobilebodies, which panels in this instance are of two- 35 ply laminatedstructure comprising a foundation or backing strip of relatively stiffbut flexible material and a facing strip of cloth or trim fabric. Theinvention, however, is not limited to the production of two-plycomposite trim 40 panels as it may be equally adapted for the productionof panels consisting of three or more plies. Usually the trim panel iscomposed of a base or backing material, such as cardboard or ply-board,but as a result of the present inven- 45 tion I may employ a strip offine wire mesh as a backing for the cloth or fabric, and when using wiremesh I prefer to apply a backing or bottom covering strip to the wiremesh which may be a strip of paper. 50

In Figs. 2 and 4 there is illustrated, by way of example, one form oftrim panel F which may be produced in the apparatus. In this instancethe panel comprises a foundation or backing portion A to which iscemented a top fabric portion B. The composite panel is pressed toprovide a suitable pattern such as the embossed portion C and piercedopenings D and E.

Referring to the apparatus, the backing strip A is carried in coiledform on a supply roll 9 supported for rotation'on suitable uprights Ill.The strip A passes between a pair of guide and straightening rollersunderneath the nozzle |2a of a tank or container l2 which may contain,as in the present instance, a supply of liquid cement. The mouth of thenozzle |2a is fiattened to provide a narrow transverse orificeprojecting the full width of the strip A so as to coat the entiresurface with cement during the travel of the strip. Thence, the strippasses between a pair of spreader rollers l3 for spreading the cement onthe strip in an even and uniform manner. The strip is then fed beneath afan |4 located within an open mouth casing I5. This fan is driven by asuitable motor Ma and operates to direct an air stream against thecemented face of the strip and partially dry the cement so that it willhave the proper tacky consistency. Other suitable drying means may beutilized in place of the fan if desired.

The facing strip B is wound and carried on a supply roller IS, thepivots H of which are supported in bearings at the upper ends of a pairof pedestals I8. Resistance is provided to the pulloff of the strip fromthe roll by means of friction blocks I9 engaging the pivots |1 under thepressure of springs 20.

The superimposed strips are guided into superimposed relation and causedto pass between a pair of presser rollers 29 and 30 which function topress the strips together and effect a permanent bond by virtue of thecement or adhesive material between the strips. The lower presserrollers 30 is preferably joumaled in fixed bearings in a pair oflaterally spaced uprights 23. The upper presser roller 29 is preferablyjournaled in a pair of slide blocks 3| which are adjustable in verticalways in the uprights 23 and are carried by a pair of screw shafts 32threaded through tapped holes in the cross heads 23a. The shafts arerotated to adjust the presser roller 29 by means of hand wheels 33. Theblocks 3| are adjustable against the action of compression springs 34and by virtue of the adjusting means for the roller 29 it will be seenthat the presser rollers may be properly positioned to accommodate anythickness of the laminated strip.

The united strips A and B are guided from the presser rolls 29 and 30between a pair of stretcher rollers 2| and 22. The lower roller 22rotates in fixed bearings in a pair of spaced uprights 31. The upperroller 2| is journalled in a pair of slide blocks 24 which slide invertical ways, as

shown, in the uprights 31. The slide blocks 24 are carried at the lowerends of a pair of screw threaded shafts 25 which extend through tappedholes in the cross heads 26 and are operated by means of hand wheels 21.The slide blocks 24 preferably work against compression springs 28interposed between the blocks and the bottoms of the guideways. Theupper stretcher roller 2| is provided at opposite ends with reversespiral threads 2|a by means of which the side edges of the fabric B arepulled laterally so as to stretch the fabric and render it smooth andunwrinkled before the strips are fed between the forming rollers. Sincethe roller 2| may be adjusted vertically it will be seen that the biteof the stretcher roller' on the fabric may be properly regulated.

From the stretcher rollers the laminated strip is then guided between apair of forming rollers 35 and 36 carried by uprights 31 and which, inthe present instance, are power driven and function as means for feedingthe strips A and B through the machine. Attached to the roller 35 is aring gear 38 which meshes with a gear 39 carried by the lower roller 36.The gear 38 is driven by a gear 40 from a shaft 4| which may be operatedthrough suitable reduction gearing from an electric motor. The stubshafts 42 of the lower roller 36 are joumaled in bearings in theuprights 31. The upper roller 35 is free to rotate on a non-rotatablecross shaft 43 the opposite ends of which are secured in guide blocks 44slidable in vertical ways 44a in the uprights 31. These guide blocks arecarried by screw shafts 45 operable by means of hand wheels 46. Theadjusting shafts 45 cooperate with the threads of tapped holes in thecross heads 31a. The slide blocks 44 are'adjustable against compressionsprings 41 located at the bottom of the ways 4411. By virtue of theabove described adjusting means the proper relative positions of thepattern forming rollers may be determined. In the present instance theforming rollers are provided with duplicate patterns so that at eachcomplete revolution the rollers will repeat the same pattern twice inthe length of the laminated strip. Obviously the rollers may be of asize to produce a lesser or greater number of duplicate patterns, eachcomplete pattern ordinarily being used for a single panel F. In thepresent instance the upper roller is provided with projecting portions50 mating with correspondingly shaped 35 recesses in the face of thelower roller 36 for piercing the laminated strip so as to produce theopenings E in the panel. The upper roller also has opposed projectingportions 48 mating with correspondingly shaped recesses in the lowerroller for piercing the strip to form the openings D. The patternrollers in this instance also are provided with grooves or channelportions 49 on the upper roller mating with correspondingly shapedprojections or ribs on the lower roller by means of which the embossedportion C is pressed into the laminated sheet, as shown in Fig. 4.

The pattern forming rollers are also provided with means for shearingthe strip transversely into the successive panels F. To this end the 50upper roller 35 may be provided with diametrically opposed knives 5| andthe lower roller with recesses 5|a into which the knives are shifted toshear the strip. Each knife 5| is in the form of a plunger slidable in aslot in the roller 35 and carrying at its inner end a cam roller 52adapted to contact with a cam 53 secured to the shaft 43. The cam rollerand cam are located within a recess 54 in the hub of the roller 35.Hence, during the rotation of the roller 35 cam rollers 52 willsuccessively travel into position to contact with cam 53 whereupon theknives 5| will be successively shifted outwardly from the face of theroller to shear the strip during its travel. In the present instance twopanels F will be cut from the strip by the knives 5| at each revolutionof the forming rollers 35 and 3B. These rollers are also provided ateach side with cooperating cutting means for trimming the longitudinaledges of the strip. In the present instance the trimming means comprisesan annular projecting portion 55 at each end of the upper roller 35which travels in a groove in the lower roller and operates to trim offthe portions 56 at the longitudinal edges of the strip.

Where the pattern formed in the blank includes openings pierced orpunched in the strip,

the slugs may be ejected in any suitable manner. In the foregoingembodiment the lower roller 36 may be hollow, as shown, and the slugspunched from the strip-pass directly into the interior of the roller.These may be discharged by directing an air blast through the roller.

It will be understood that where the laminated strip consists of morethan two plies, an additional supply roller or rollers and cementingmeans are provided as needed, all strips being joined together and fedcontinuously to the pattern forming rollers.

From the foregoing it will be seen that the pattern forming rollers 35and 36 are, in the present preferred embodiment of the invention,provided with means for pressing an embossed design in thelaminatedstrip, piercing openings therein, trimming the edges of thestrip, and cutting off the strip transversely, all of which may beaccomplished simultaneously during thecontinuous travel of the stripthrough the machine.

Referring to the embodiment illustrated in Figs. to 8 inclusive, theapparatus in this instance is constructed, by way of example, to form asuccession of panels F out of flexible material, such' as sheet steel.Any suitable pattern may be produced, and in Fig. 6 there is illustrateda panel having an embossed portion H, openings J and an aperture K. Thesheet metal strip is coiled and supported on a supply-roll 60 from whichit is fed through guide and straightening rollers 62, Thence the striptravels continuously between the pattern forming rollers 63 and 64. Theshaft 65 of the upper roller 63 is driven through meshing gears 66 and6'! from a drive shaft 68 which in turn is driven from an electric motoror other power source.

The upper roller in this instance is provided with a projecting portion69 working in a groove 10 in the lower roller and designed to press intothe strip the embossed portion H. As in the previous embodiment therollers are provided with.

duplicate pattern forming portions so as to repeat the pattern twiceduring each revolution of the rollers. The upper roller also hasprojections ll adapted to coact with the edges of correspondingly shapedrecesses in the lower roller to pierce the sheet and produce theopenings J. The upper roller also is provided with diametrically opposedprojecting portions 12 adapted to coact with the edges of recesses 13 inthe lower roller to punch out the portions 14 to produce apertures K.For the purpose of removing the slugs 14 the punch portion 12 cooperateswith a knock-out plunger 15 located in the recess I3. The plunger 15 iscarried by a sliding guide rod- 16 and works against a spring II. Itwill be un- 5 derstood that after the rollers have revolved past thepoint where the slug I4 is punched from the strip the plunger 15 will beshifted by the spring to eject the slug from the lower roller.

The pattern forming rollers are also provided 10 with mechanism fortrimming the edges of the strip. This mechanism comprises annularcutting projections 18 cooperating with the edges of grooves 19 in thelower roller to trim oif the edge portions 80 of the strip continuouslyduring its 15 travel, as shown in Fig.

From the foregoing it will be seen that the strip during its continuoustravel through the machine may be simultaneouslyfembossed, pierced andtrimmed. At the same time the blanks F 20 are cut off from the strip,two during each revolution of the rollers, by means of transverse knives5| constructed and operating similar to the knives 5| above described inconnection with the embodiment illustrated in Figs. 1 to 4 inelusive.

I claim:

1. The method of forming laminated panels, which comprises guiding abacking strip and a. fabric strip into superimposed relation, unitingsaid strips together during the travel thereof continuously in apredetermined path, and thereafter stretching the fabric strip uniformlyacross the backing strip.

2. The method of forming laminated panels, which comprises guiding abacking strip and a. fabric strip into. superimposed relation, unitingsaid strips together during the travel thereof continuously in apredetermined path, thereafter stretching the fabric strip uniformlyacross the backing strip, and thereafter embossing said laminated strip.

3. The method of forming laminated panels, which comprises guiding abacking strip and a fabric strip into superimposed relation, uniting.said strips together during the travel thereof continuously in apredetermined path, thereafter stretching the fabric strip uniformlyacross the backing strip, thereafter embossing said lam- 5 inated stripto form a succession of repeated patterns, and shearing the strip intoblanks each containing a pattern.

ALBERT P. BALL.

